Spring assemblies and bedspring made therefrom and methods of making the same

ABSTRACT

A spring assembly has two substantially parallel wires. Coil springs are successively spaced along the length of the wires, each coil spring having an axis oriented in a direction substantially normal to the parallel direction of the wires and having a coil turn at one end of the coil spring in contact with each of the two wires. Staples are utilized to connect the coil turn at each point of contact with the wires. Also described is a bedspring having a substantially rectangular frame having two pairs of opposite sides. Spring assemblies as above described are placed adjacently to one another in parallel relationship, each extending between one pair of opposite sides while being parallel to the other pair of opposite sides. Cross wires are extended between the frame sides transversely to the respective spring assemblies and welded to the wires of each spring assembly at each crossing point. By deleting alternately spaced coil springs from either transversely or longitudinally disposed spring assemblies, a grid of transverse and longitudinal spring assemblies are formed of which is advantageously welded to transverse and longitudinal cross wires as well as to respective opposite frame sides. A method of forming a spring assembly and a method of forming bedsprings from the spring assemblies are also described.

United States Patent 1 Larkin 1 Dec. 24, 1974 SPRING ASSEMBLIES AND BEDSPRING MADE THEREFROM AND METHODS OF MAKING THE SAME [76] Inventor: Sam Larkin, 254 Beach 140th St.,

Belle Harbor, NY.

[22] Filed: Jan. 16, 1973 [21] Appl. No.: 324,239

Primary Examiner-James C. Mitchell Attorney, Agent, or Firm-Friedman & Goodman [57] ABSTRACT A spring assembly has two substantially parallel wires.

Coil springs are successively spaced along the length of the wires, each coil spring having an axis oriented in a direction substantially normal to the parallel direction of the wires and having a coil turn at one end of the coil spring in contact with each of the two wires. Staples are utilized to connect the coil turn at each point of contact with the wires. Also described is a bedspring having a substantially rectangular frame having two pairs of opposite sides. Spring assemblies as above described are placed adjacently to one another in parallel relationship, each extending between one pair of opposite sides while being parallel to the other pair of opposite sides. Cross wires are extended between the frame sides transversely to the respective spring assemblies and welded to the wires of each spring assembly at each crossing point. By deleting alternately spaced coil springs from either transversely or longitudinally disposed spring assemblies, a grid of transverse and longitudinal spring assemblies are formed of which is advantageously welded to transverse and longitudinal cross wires as well as to respective opposite frame sides. A method of forming a spring assembly and a method of forming bedsprings from the spring assemblies are also described.

3 Claims, 6 Drawing Figures C M O 12 SPRING ASSEMBLIES AND BEDSPRING MADE THEREFROM AND METHODS OF MAKING THE SAME BACKGROUND OF THE INVENTION The present invention generally relates to spring assemblies and bedsprings made therefrom and methods of making the same, and more particularly to a novel spring assembly and bedspring which is substantially more economical to manufacture and which is easier to use in the construction of bedsprings and like furniture and the methods of making the same.

Numerous coil spring assemblies utilized in seats, bedsprings, and other like furniture are already known. The procedures commonly utilized in the assembly of such furniture includes the provision of a frame which is typically in the form of a wire matrix formed of spaced and mutually perpendicular wires. Adjacent wires are typically spaced from each other distances which correspond with the diameters of the coil springs which are mounted thereon. The known methods of making bedsprings, for example, are, however, frequently cumbersome and expensive. The manufacturing or construction of the spring arrangements is further complicated and made more costly by the requirement that the coil springs be individually mounted on the wire matrix connected to the frame member usually manually. Thus, the general approach utilized in the prior art has included the steps of, first, forming a frame on which coil springs can be mounted and, secondly, forming a wire matrix mounted on the frame, and, thirdly, mounting individual coil springs on the completed frame. As suggested above, this prior art technique was cumbersome, inefficient and, therefore, costly.

SUMMARY OF THE INVENTION Accordingly, it is an object of the present invention to provide a bedspring which does not have the disadvantages associated with similar spring arrangements known in the prior art.

It is another object of the present invention to provide a spring assembly of the type under discussion which is simple in construction and economical to manufacture.

It is still another object of the present invention to provide a spring assembly as above described which is especially adapted for mass production.

It is yet another object of the present invention to provide a spring assembly having a single row of coil springs which may be manufactured in standardized sizes and which can, at a later date, be easily and rapidly assembled into a bedspring having desired dimensions.

It is a further object of the present invention to provide a bedspring which is constructed from spring assemblies of the type suggested in the last mentioned object.

It is still a further object of the present invention to provide a method of forming a spring assembly as suggested in the aforementioned objects.

It is yet a further object of the present invention to provide a method of forming a bedspring from spring assemblies as above suggested.

In order to achieve the above objects, as well as others which will become apparent hereafter, a spring assembly in accordance with the present invention comprises two spaced substantially parallel wires. A plurality of coil springs are provided which are spaced from each other along the length of said wires, each coil spring having an axis oriented in a direction substantially normal to said parallel direction of said wires and having a portion in contact with each of said wires. Connecting means are provided for securing each contacting portion of each spring to each of said respective wires.

In accordance with a presently preferred embodiment, each coil turn comprises a coil, in contact with said wires, which defines a plane substantially normal to the axis of the respective coil and which has a diameter greater than the spacing between said wires. In this manner, each coil turn contacts each wire at two points. Said connecting means comprises a staple which clamps said turn to said wires at each point of contact.

A bedspring in accordance with the present invention comprises a substantially rectangular frame having two pairs of opposite sides. A plurality of longitudinal elongated spring assemblies, of the type above described, each extend between one pair of opposite sides while being parallel to the other pair of opposite sides.

In accordance with one presently preferred embodiment of the bedspring, the coil springs on each of the longitudinal elongated spring assemblies are spaced from each other desired distances. A plurality of spaced substantially parallel transverse cross wires are provided which extend between and are connected to the other pair of opposite sides of the bedspring frame. The transverse cross wires and parallel wires of the longitudinal spring assemblies may be welded to each other or connected in any other conventional means at each cross point therebetween. Optionally, a plurality of spaced parallel longitudinal cross wires may be provided which extend between and are connected to said one pair of opposite sides and respectively positioned between said longitudinal spring assemblies. Said transverse and longitudinal cross wires are connected to each other to provide a cross wire grid which supports its spring assemblies and maintains the latter in spaced parallel relation.

According to another presently preferred embodiment of the bedspring, the spacing between adjacent coil springs on said longitudinal spring assemblies is selected to be twice a desired predetermined spacing. The coil springs of adjacent longitudinal spring assem blies are aligned along lines parallel to said one pair of opposite sides. A plurality of spaced transverse elongate spring assemblies each extending between and connected to said other pair of opposite sides are provided which are parallel to said one pair of opposite sides. The transverse spring assemblies are spaced from each other twice the predetermined spacing and are so arranged so that each transverse spring assembly extends midway between corresponding spaced coil springs on said longitudinal spring assembly. Said transverse spring assemblies have spaced springs spaced from each other distances equal to the spacing between adjacent longitudinal spring assemblies. In this manner, the coil springs of both said transverse and longitudinal spring assemblies form an array of spaced springs having the desired spacing therebetween. As with the first preferred embodiment of the bedspring, longitudinal and transverse cross wires may be provided to form a grid to which the parallel wires of the longitudinal and transverse spring assemblies are connected by conventional means.

A method of forming a spring assembly in accordance with the present invention comprises the steps of advancing two spaced substantially parallel wires in a predetermined direction past a mounting station. Successive coil springs are then positioned in contacting relation with said wires as the latter advance to thereby position said springs in spaced relation to each other along said wires. Each spring is then secured to each of said wires.

The present invention also contemplates the method of forming the above described spring assemblies.

BRIEF DESCRIPTION OF THE DRAWINGS With the above and additional objects and advantages in view, as will hereinafter appear, this invention comprises the devices, combinations and arrangements of parts hereinafter described and illustrated in the accompanying drawings of a preferred embodiment in which:

FIG. 1 is a top plan view of a spring assembly in accordance with the present invention, showing the coil springs mounted on two parallel wires;

FIG. 2 is a front elevational view of the coil spring assembly of FIG. 1;

FIG. 3 is a top plan view ofa bedspring frame which includes a grid of longitudinal and transverse cross wires connected between opposite sides of the frame;

FIG. 4 is a top plan view ofa first embodiment of the bedspring in accordance with the present invention, showing a plurality of longitudinal bedspring assemblies of FIGS. 1 and 2 mounted on the bedspring frame shown in FIG. 3;

FIG. 5 is a top plan view of a second embodiment of a bedspring in accordance with the present invention, at an intermediate stage of production, wherein a plurality of longitudinal bedspring assemblies are mounted on the frame of FIG. 3 each having spring coils mounted thereon distances twice the desired distance;

and

FIG. 6 is a top plan view of the completed bedspring shown in FIG. 5, wherein a plurality of transverse bedspring assemblies are mounted between adjacent transverse rows of coil springs of the longitudinal spring assemblies.

I DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to the FIGURES, in which similar or identical parts have been designated by the same reference numerals, and first referring to FIG. 1, a spring assembly in accordance with the present invention is generally designated by the reference numeral 10. The spring assembly 10 comprises two substantially parallel spaced wires 12. The wires 12 can be made from any suitable material commonly used in making bedspring framesand like furniture. Mounted in spaced relaton along the length of the wires 12 are a plurality of coil springs designated by the reference numeral 14.

Referring to FIGS. 1 and 2, the coil springs 14 are shown to be of the single-cone type each having a coil turn 16 at one end thereof which is substantially in a plane normal to the axis of the coil springs. Extending upwardly from the coil turns 16 are the upper helical portions 18. The materials utilized for and the details of construction of the coil springs are conventional and known to those skilled in the art. The diameters of the coil turns 16 are selected to be greater than the spacing between the two wires 12 or alternately, the spacing between the wires 12 is selected to be smaller than the diameter of the coil turns 16. The coil turns 16 are positioned in contacting relation with the two parallel wires 12 and, consequently, each coil turn contacts each wire along two points. Connecting means of any suitable or conventional type may be utilized for connecting or securing the coil turns 16 to the wires 12. Shown in FIGS. 1 and 2 are staples 20 for connecting springs to the wires.

The coil assembly 10 shown in FIGS. 1 and 2 is particularly suitable for manufacture in accordance with mass production techniques. Thus, although the wires 12 are shown to have finite lengths, the presently preferred method of forming the spring assemblies 10 is to advance two continuous spaced substantially parallel wires in a predetermined direction past a mounting station. The wires 12 can be advanced, forexample, from two spaced rolls of wire. Successive coil springs 14 are then positioned in contacting relation with the wires 12 as the latter advance to thereby position the springs 14 in spaced relation to each other along the wires 12. More particularly, as the wires advance, the coil turns of the respective successive springs are positioned on the wires 12 as shown in FIGS. 1 and 2. The staples 20, or other retaining means may then be provided either at the mounting station or soon after the coil springs and the wires have moved beyond the station.

According to the presently preferred embodiment, the method further comprises the step of forming each coil at the mounting station prior to positioning the same on the wires. It should be made clear, however, that the coil springs may be preformed and supplied at the mounting station where the coils are merely positioned onto the wires.

As suggested above, the wires are advantageously advanced from continuous rolls the preferred method further comprising the step of cutting the wires to desired lengths, before or after the coil springs have been mounted thereon, so as to provide a desired number of coil springs on the cut lengths of the wire 12.

The spring assemblies 10 as above described are particularly suitable for manufacture in accordance with mass production techniques since it is possible to continuously pass an elongate wire arrangement past a mounting station. It should be clear that such manufacture provides continuous and efficient operation.

The spring assemblies 10 may be manufactured in different sizes and different lengths. After the spring assemblies have been formed as above described, they can be stored and shipped as units which can be assembled into various bedsprings as to be described in connection with FIGS. 3-6. By adjusting the coil spring forming machine and the means for cutting the wires 12, the spring assemblies 10 can be formed in a variety of dimensions. Changing the speed of advancement of the wires 12 past the mounting station or changing the rate at which the springs are mounted on other wires changes the spacing between the adjacent coil springs. As should be clearly evident, the method as above described provides great flexibility in the nature of spring assemblies 10 which can be formed.

In FIG. 3, a rectangular bedspring frame has two pair of opposite sides which are mutually perpendicular to each other one pair of opposite sides being designated by the reference numeral 32 and the other pair of opposite sides being designated by the reference numeral 34. For purposes of the specification as well as the claims, the pair of sides 32 are termed directed transversely to the long length of the bedspring frame while the pair of opposite sides 34 are termed to be longitudinal or along the long length of the bedspring frame. These terms are merely used for purposes of orientation and are not to be deemed as limiting or critical insofar a the invention is concerned. The sides 32 and 34 are conventional and may be made from any wire or material commonly used for that purpose.

A plurality of transverse cross wires 33 are spaced from each other uniformly along the length of the bedspring while a plurality of spaced longitudinal cross wires 35 are positioned along the width of the bedspring so as to form, together with the transverse cross wires, a grid which is suitable for supporting the bedspring assemblies as, to be described hereafter. The cross wires may each be connected at their ends 31 to their respective opposite frame sides in any conventional manner, e.g., by welding. Advantageously, the transerse and longitudinal cross wires are connected to each other at each cross point 36 therebetween in the grid by welding. The specific spacing selected between the transverse and longitudinal cross wires will become evident from the description of FIGS. 4-6.

Referring to FIG. 4, a section or corner of a bedspring is shown and generally designated by the reference numeral 30. A plurality of longitudinal spring assemblies, as described in connection with FIGS. 1 and 2, extend between the sides or wires 32 in such a manner so that the wires 12 are substantially parallel to the sides or wires 34. The ends of the wires 12 are bent to provide twists 36 which secure the ends of the wires 12 to the wires 32. Any other suitable means for connecting the ends of the wires 12 to the wires 32 may be used.

Conventional bedsprings typically have nine rows of coil springs along the longitudinal length thereof, while having five to seven columns of springs along the width thereof. The coil springs 14 are normally so arranged so that the distances between adjacent coil springs along the longitudinal direction is equal to the distance between adjacent coil springs in the transverse direction. In accordance with the first embodiment of the bedspring, the coil springs on each of the longitudinal spring assemblies 10 is spaced from an adjacent coil spring in a longitudinal direction a predetermined desired distance. In the construction of the bedspring, adjacent spring assemblies 10 are spaced from each other the same desired predetermined distance so that a desired square coil spring array is obtained.

Advantageously, the longitudinal cross wires 35 are also spaced from each other said predetermined desired distance and each of the longitudinal spring assemblies is mounted midway between adjacent longitudinal cross wires or midway between a longitudinal cross wire and a corresponding frame side 34. As well be noted, the longitudinal cross wires 35 are only connected to the frame side 32 and the transverse cross wires 33. Being parallel to the wires 12 of the longitudinal spring assemblies 10, the cross wires 35 are not connected directly to the wires 12. Although the provision of the longitudinal cross wires 35 is optional, they assist to strengthen the frame grid and the completed bedspring.

The bedspring 30 is therefore constructed by simply forming a substantially rectangular frame and extending the preformed spring assemblies 10 in parallel relationship between two opposite wires of the frame. It will be appreciated that the assembly of the bedspring is thereby substantially less cumbersome and time consuming as compared to comparable spring assemblies and methods of forming the same known in the prior art. Thus, the technician who assembles the bedspring 30 need not concern himself with connecting the individual coil springs to the wires 12. This has been done in advance.

Referring to FIGS. 3, 5 and 6, another presently preferred embodiment of a bedspring is shown. The same frame illustrated in FIG. 3 will be utilized in the construction of the second embodiment of the bedspring. However, a plurality of longitudinal coil spring assemblies 10 are provided each of which has coil springs 14 spaced therealong. The space between adjacent coil springs 14 on each coil assembly 10 is twice a predetermined desired spacing. More particularly, the spacing between adjacent coil springs in the longitudinal direction is selected to be twice the spacing between adjacent coil springs in the transverse rows formed by adjacent coil assemblies 10. Otherwise, the coil assemblies 10' are similarly constructed as are the coil assemblies 10 of FIGS. 1 and 2.

In FIG. 6, a plurality of spaced transverse coil assemblies 10" are provided each of which has coil springs spaced therealong at distances equivalent to the distances between adjacent coil springs 14 on the longitudinal spring assemblies 10 in the transverse direction. Each spring assembly 10' is positioned midway between two rows of transverse coil springs 14 mounted on the longitudinal spring assemblies 10'. The parallel wires 12 of each of the transverse spring assemblies 10" are connected at their ends to the frame side 34 in any conventional manner and are connected to the longitudinal cross wires 35 as well as to the parallel wires 12 of the longitudinal spring assemblies 10' at each respective cross point therewith.

As described in connection with FIG. 4, it now becomes evident that the spacing between adjacent transverse cross wires 33 is similarly selected to be equal to the predetermined desired spacing between adjacent coil springs in the completed bedspring. The cross wires and the parallel coil assembly wires may be connected to each other at their respective cross points in any conventional manner such as by welding.

Both embodiments described include nine coil springs in the longitudinal direction while having five coil springs in the transverse direction. Accordingly, eight transverse cross wires 33 and four longitudinal cross wires 35 are provided to provide a grid having 45 rectangular spaces one space for each coil spring positioned centrally therein. Additional cross wires may, of course, be provided to further strengthen the bed spring assembly if such extra strength is necessary.

Due to the large number of transverse and longitudinal wires which result in the above described bedspring constructions, the various wires are advantageously so arranged so as to minimize the thickness or height of the bedspring. Thus, in the embodiment of FIG. 4, the transverse cross wires 33 are located in one plane while the longitudinal cross wires 35 and the parallel wires 12 are each substantially in the same plane directly above the plane of the transverse cross wires. Similarly, the bedspring shown in FIG. 6 has the longitudinal cross wires 35 as well as the longitudinal parallel wires of the spring assemblies 10' in one plane while the transverse cross wires 33 and parallel wires 12 of the transverse spring assemblies 10" are located in substantially the same plane directly above the plane in which the longitudinal wires are disposed. In this manner, in each embodiment, all the wires lie in a space approximately equal to twice the diameters or cross dimensions of the wires.

If desired, the longitudinal wires 12 of the spring assemblies 10 and the transverse wires 12 of the transverse spring assemblies 10 in the embodiment of FIG. 6, may also be connected to each other at their respective cross points. However, due to the presence of the coil springs 14 in the region of the cross points, this may be inconvenient. It is not deemed necessary that such connections be made if the parallel wires of each of the spring assemblies are connected to respective cross wires at all cross points. The longitudinal and transverse cross wires in FIG. 3 are normally connected to each other. Such connections between cross wires advantageously takes place prior to the positioning of spring assemblies onto the frame grid.

Numerous alterations of the structure herein disclosed will suggest themselves to those skilled in the art. However, it is to be understood that the present disclosure relates to a preferred embodiment of the invention which is for purposes of illustration only and is not to be construed as a limitation of the invention.

What is claimed is:

l. A bedspring comprising a substantially rectangular frame having two pairs of opposite sides; a plurality of longitudinal elongate spring assemblies spaced from each other a predetermined distance and each extending between and connected to one pair of opposite sides while being parallel to the other pair of opposite sides, each spring assembly comprising a pair of spaced substantially parallel wires, a plurality of coil springs uniformly spaced from each other twice said predetermined distance and mounted on said pair of parallel wires, coil springs of adjacent longitudinal spring assemblies being aligned along lines parallel to said one pair of opposite sides; and a plurality of transverse elongate spring assemblies each extending between and connected to said other pair of opposite sides, said transverse spring assemblies being spaced from each other twice said predetermined distance, each transverse spring assembly being positioned midway between adjacent corresponding spaced coil springs on said longitudinal spring assemblies, said transverse spring assemblies being provided with coil springs uniformly spaced from each other said predetermined distance and aligned with said coil springs on said longitudinal spring assemblies, whereby the coil springs on both said transverse and longitudinal spring assemblies form an array of spaced springs spaced from each other said predetermined distance in both the longitudinal and transverse directions of the bedspring.

2. A bedspring as defined in claim 1, wherein each of said coil springs has an axis oriented in a direction substantially normal to said parallel direction of said wires of said spring assemblies and has a portion in contact with each of two corresponding wires on which a respective coil spring is mounted, and connecting means for securing each portion of each spring to each of said wires.

3. A bedspring as defined in claim 1, further comprising longitudinal cross wires provided between adjacent longitudinal spring assemblies and connected at opposite ends to said one pair of opposite sides; and transverse cross wires provided between adjacent transverse spring assemblies and connected at opposite ends to said other pair of opposite sides, said cross wires being connected to each other at respective crossing points therebetween, the parallel wires of said longitudinal spring assemblies being connected to said transverse cross wires and the parallel wires of said transverse spring assemblies being connected to said longitudinal cross wires at respective crossing points therebetween, whereby said cross wires support said spring assemblies and maintain respective ones of said assemblies in parallel relation to each other. 

1. A bedspring comprising a substantially rectangular frame having two pairs of opposite sides; a plurality of longitudinal elongate spring assemblies spaced from each other a predetermined distance and each extending between and connected to one pair of opposite siDes while being parallel to the other pair of opposite sides, each spring assembly comprising a pair of spaced substantially parallel wires, a plurality of coil springs uniformly spaced from each other twice said predetermined distance and mounted on said pair of parallel wires, coil springs of adjacent longitudinal spring assemblies being aligned along lines parallel to said one pair of opposite sides; and a plurality of transverse elongate spring assemblies each extending between and connected to said other pair of opposite sides, said transverse spring assemblies being spaced from each other twice said predetermined distance, each transverse spring assembly being positioned midway between adjacent corresponding spaced coil springs on said longitudinal spring assemblies, said transverse spring assemblies being provided with coil springs uniformly spaced from each other said predetermined distance and aligned with said coil springs on said longitudinal spring assemblies, whereby the coil springs on both said transverse and longitudinal spring assemblies form an array of spaced springs spaced from each other said predetermined distance in both the longitudinal and transverse directions of the bedspring.
 2. A bedspring as defined in claim 1, wherein each of said coil springs has an axis oriented in a direction substantially normal to said parallel direction of said wires of said spring assemblies and has a portion in contact with each of two corresponding wires on which a respective coil spring is mounted, and connecting means for securing each portion of each spring to each of said wires.
 3. A bedspring as defined in claim 1, further comprising longitudinal cross wires provided between adjacent longitudinal spring assemblies and connected at opposite ends to said one pair of opposite sides; and transverse cross wires provided between adjacent transverse spring assemblies and connected at opposite ends to said other pair of opposite sides, said cross wires being connected to each other at respective crossing points therebetween, the parallel wires of said longitudinal spring assemblies being connected to said transverse cross wires and the parallel wires of said transverse spring assemblies being connected to said longitudinal cross wires at respective crossing points therebetween, whereby said cross wires support said spring assemblies and maintain respective ones of said assemblies in parallel relation to each other. 